Battery systems, battery modules, and method for cooling a battery module

ABSTRACT

Battery systems, battery modules, and a method for cooling a battery module are provided. The battery module includes a battery cell having a first side and a second side, and a first graphite sheet disposed on the first side of the battery cell that conducts heat energy from the battery cell into the first graphite sheet to cool the battery cell. The battery module further includes a first cooling manifold coupled to the first graphite sheet that conducts heat energy from the first graphite sheet into the first cooling manifold. The first cooling manifold is further configured to receive a fluid that flows therethrough to conduct heat energy from the first cooling manifold into the fluid.

TECHNICAL FIELD

This application relates to battery systems, battery modules, and amethod for cooling the battery module.

BACKGROUND OF THE INVENTION

In a typical air-cooled battery pack, ambient air from ambientatmosphere is directed across battery cells in the battery pack and issubsequently exhausted from the battery pack. However, the typicalair-cooled battery pack has a major challenge in maintaining atemperature of the battery pack within a desired temperature range.

In particular, a maximum operating temperature of the battery cells canoften be less than a temperature of ambient air utilized to cool thebatteries. In this situation, it is impossible to maintain the batterycells within a desired temperature range in an air-cooled battery pack.

Accordingly, the inventors herein have recognized a need for an improvedbattery system having a battery module and method for cooling thebattery module that minimizes and/or eliminates the above-mentioneddeficiency.

SUMMARY OF THE INVENTION

A battery module in accordance with an exemplary embodiment is provided.The battery module includes a battery cell having a first side and asecond side. The battery module further includes a first graphite sheetdisposed on the first side of the battery cell that conducts heat energyfrom the battery cell into the first graphite sheet to cool the batterycell. The battery module further includes a first cooling manifoldcoupled to the first graphite sheet that conducts heat energy from thefirst graphite sheet into the first cooling manifold. The first coolingmanifold is further configured to receive a fluid that flowstherethrough to conduct heat energy from the first cooling manifold intothe fluid.

A battery system in accordance with another exemplary embodiment isprovided. The battery system includes a battery module having a batterycell, a first graphite sheet, and a first cooling manifold. The batterycell has a first side and a second side. The first graphite sheet isdisposed on the first side of the battery cell and conducts heat energyfrom the battery cell into the first graphite sheet to cool the batterycell. The first cooling manifold is coupled to the first graphite sheetand conducts heat energy from the first graphite sheet into the firstcooling manifold. The first cooling manifold is further configured toreceive a refrigerant that flows therethrough to conduct heat energyfrom the first cooling manifold into the refrigerant. The battery systemincludes a condenser fluidly coupled to the battery module. Thecondenser is configured to receive the refrigerant from the batterymodule and to extract heat energy from the refrigerant. The condenser isfurther fluidly coupled to a compressor and configured to route therefrigerant to the compressor. The compressor is further fluidly coupledto the first cooling manifold of the battery module. The compressor isconfigured to pump the refrigerant into the first cooling manifold.

A battery system in accordance with another exemplary embodiment isprovided. The battery system includes a battery module having a batterycell, a first graphite sheet, and a first cooling manifold. The batterycell has a first side and a second side. The first graphite sheet isdisposed on the first side of the battery cell and conducts heat energyfrom the battery cell into the first graphite sheet to cool the batterycell. The first cooling manifold is coupled to the first graphite sheetand conducts heat energy from the first graphite sheet into the firstcooling manifold. The first cooling manifold is further configured toreceive a coolant therethrough to conduct heat energy from the firstcooling manifold into the coolant. The battery system further includes aheat exchanger fluidly coupled to the battery module. The heat exchangeris configured to receive the coolant from the battery module therein andto extract heat energy from the coolant flowing therethrough. Thebattery system further includes a cold plate fluidly coupled to the heatexchanger. The cold plate is configured to extract heat energy from thecoolant flowing therethrough. The battery system further includes areservoir fluidly coupled between the cold plate and a pump. Thereservoir is configured to receive the coolant from the cold plate andto route the coolant to the pump. The pump is further fluidly coupled tothe first cooling manifold of the battery module. The pump is configuredto pump the coolant from the reservoir into the first cooling manifold.

A method for cooling a battery module in accordance with anotherexemplary embodiment is provided. The battery module has a battery cell,a first graphite sheet, and a first cooling manifold. The methodincludes conducting heat energy from the battery cell into the firstgraphite sheet disposed on a first side of the battery cell to cool thebattery cell. The method further includes conducting heat energy fromthe first graphite sheet into the first cooling manifold coupled to thefirst graphite sheet. The method further includes receiving a fluid inthe first cooling manifold and conducting heat energy from the firstcooling manifold into the fluid in the first cooling manifold.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic of a battery system in accordance with anexemplary embodiment;

FIG. 2 is a schematic of a battery module utilized in the battery systemof FIG. 1 in accordance with another exemplary embodiment;

FIG. 3 is another schematic of the battery module of FIG. 2 having firstand second top caps removed from first and second cooling manifolds,respectively, in the battery module;

FIG. 4 is another schematic of the battery module of FIG. 2;

FIG. 5 is a schematic of graphite sheets and first and second coolingmanifolds utilized in the battery module of FIG. 2;

FIG. 6 is a schematic of a graphite sheet utilized in the battery moduleof FIG. 2;

FIG. 7 is another schematic of the graphite sheet of FIG. 6;

FIG. 8 is a schematic of a cooling manifold utilized in the batterymodule of FIG. 2 in accordance with another exemplary embodiment;

FIG. 9 is a cross-sectional schematic of the cooling manifold of FIG. 8;

FIG. 10 is another cross-sectional schematic of the cooling manifold ofFIG. 8;

FIG. 11 is an enlarged schematic of the portion of the cooling manifoldof FIG. 8;

FIG. 12 is a schematic of a top portion of the battery module of FIG. 2illustrating graphite sheets and a portion of the cooling manifold ofFIG. 11;

FIG. 13 is a schematic of an extrusion device and a brazing deviceutilized to construct the cooling manifold of FIG. 8;

FIG. 14 is a flowchart of a method for constructing the cooling manifoldof FIG. 8 in accordance with another exemplary embodiment;

FIG. 15 is a flowchart of a method for cooling the battery module in thebattery system of FIG. 1 in accordance with another exemplaryembodiment;

FIG. 16 is a schematic of a battery system in accordance with anotherexemplary embodiment; and

FIGS. 17-18 are flowcharts of a method for cooling a battery module inthe battery system of FIG. 16 in accordance with another exemplaryembodiment.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Referring to FIG. 1, a battery system 10 for generating electrical powerin accordance with an exemplary embodiment is illustrated. The batterysystem 10 includes a battery module 20, a compressor 22, a condenser 24,conduits 28, 30, 32, a temperature sensor 36, a fan 38, and amicroprocessor 40. An advantage of the battery module 20 is that thebattery module utilizes graphite sheets and cooling manifolds conductheat energy from battery cells in the battery module 20 to effectivelycool the battery cells.

For purposes of understanding, the term “fluid” means either a liquid ora gas. For example, a fluid can comprise either a coolant or arefrigerant. Exemplary coolants include ethylene glycol and propyleneglycol. Exemplary refrigerants include R-11, R-12, R-22, R-134A, R-407Cand R-410A.

Referring to FIGS. 2-4, the battery module 20 is provided to generate avoltage therein in accordance with another exemplary embodiment. Thebattery module 20 includes battery cells 80, 81, 82, 83, 84, 85, 86, 87,88, 89, 90, 91, 92, 93, graphite sheets 102, 104, 106, 108, 110, 112,114, 116, 118, 120, 122, 124, and cooling manifolds 140, 142.

The battery cells 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93are each provided to generate an operational voltage. Further, sinceeach battery cell may have an identical structure, only the structure ofthe battery cell 80 will be described in further detail. As shown, thebattery cell 80 includes a body portion 143, a peripheral extensionportion 144, and electrodes 145, 146. The body portion 143 is generallyrectangular-shaped and has the peripheral extension portion 144extending around a periphery of the body portion 143. In an exemplaryembodiment, the electrodes 145, 146 extend from a top portion of thebattery cell 80 and have an operational voltage generated therebetween.In one exemplary embodiment, each battery cell is a lithium-ion batterycell. In alternative embodiments, the battery cells could benickel-cadmium battery cells or nickel metal hydride battery cells forexample. Of course, other types of battery cells known to those skilledin the art could be utilized.

Referring to FIGS. 2 and 5, the graphite sheets 102, 104, 106, 108, 110,112, 114, 116, 118, 120, 122, 124 are provided to conduct heat energyfrom the battery cells 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91,92, 93 into the cooling manifolds 140, 142 to cool the battery cells. Inparticular, the graphite sheets and cooling manifolds can maintain thebattery cells within a desired temperature range, and in particular canmaintain the battery cells at a temperature less than a thresholdtemperature level. In one exemplary embodiment, the desired temperaturerange is 15° Celsius−35° Celsius. In another exemplary embodiment, thethreshold temperature level is 40° Celsius.

Referring to FIGS. 5-7 and 12, the graphite sheets 102, 104, 106, 108,110, 112, 114, 116, 118, 120, 122, 124 have an identical structure.Accordingly, only the structure of the graphite sheet 102 will bedescribed in greater detail below. As shown, the graphite sheet 102includes a flat panel portion 150, and an extension portion 151extending from the flat panel portion 150. The extension portion 151includes portions 152, 153, 154. The portion 152 extends from theflat-panel portion 150 (rightwardly in FIG. 12). Further, the portion153 extends from the portion 152 in a perpendicular direction (upwardlyin FIG. 12) with respect to the portion 153, and substantially parallelto the flat panel portion 150. Further, the portion 154 extends from theportion 153 in a perpendicular direction (leftwardly in FIG. 12), andsubstantially parallel to the portion 152. As shown, the graphite sheet102 is coupled to the cooling manifold 140 by inserting the portions153, 154 in the groove 210 of the cooling manifold 140. Further, theu-shaped configuration of the extension portion 151 contacts arelatively large surface area of the cooling manifold 140 to effectivelyconduct heat energy from the battery cell 80 to the cooling manifold140. In particular, each of the graphite sheets 102, 104, 106, 108, 112,114, 118, 120, 124 have an extension portion that is received within acorresponding groove of the cooling manifold 140. Further, each of thegraphite sheets 104, 110, 116, 122 have an extension portion that isreceived within a corresponding groove of the cooling manifold 142. Inan exemplary embodiment, the graphite sheets have a polyethylene coatingthereon to prevent electrical conductivity through the graphite sheets.Further, in an exemplary embodiment, each of the graphite sheets has athickness in a range of 0.5 mm to 2.0 mm. Of course, in alternativeembodiments, the graphite sheets could have a thickness greater than 2.0mm or less than 0.5 mm.

Referring to FIGS. 8-12, the cooling manifold 140 is provided to conductheat energy from the graphite sheets into a refrigerant flowing throughthe cooling manifold 140. The cooling manifold 140 includes an extrudedhousing 160, a top cap 166, a bottom cap 168, and fluid ports 170, 172.The housing 160, the top cap 166, the bottom cap 168, and the fluidports 170, 172 can be constructed from at least one of aluminum, copper,silver, gold, and alloys thereof. The extruded housing 160 defines aninterior region 162 for receiving a refrigerant therein. The housing 160defines a serpentine flow path therein from the fluid port 170 to thefluid port 172. The serpentine flow path includes the flow channels 180,182, 184, 186, 188, 190, 192, 194 that fluidly communicate with oneanother. Further, the housing 160 defines grooves 209, 210, 212, 214,216, 217, 218, 220 extending therein for receiving correspondingextension portions of graphite sheets therein. Since the grooves 210,212, 214, 216, 217, 218, 220 have an identical shape, only the shape ofgroove 210 will be explained in greater detail. In particular, thegroove 210 includes a groove portion 221 that extends into the housing160 perpendicular to a surface 223 of the housing 160. Further, thegroove 210 includes a groove portion 222 extends from an end of thegroove portion 221 parallel to the surface 223. It should be noted thatthe groove 210 does not fluidly communicate with the interior region162, nor to the other grooves of the housing 160.

It should be noted that in an alternative embodiment, the grooves in thehousing 160 of the cooling manifold 140 could have a differentconfiguration or shape than the illustrated grooves, depending on a typeof member being coupled to the cooling manifold 140 and a desiredthermal performance for conducting heat energy away from the member.Further, in another alternative embodiment, the housing 160 of thecooling manifold 140 could be constructed without any grooves and couldmerely contact a member or a fluid to conduct heat energy away from themember or the fluid.

The bottom cap 168 is fixedly coupled to a bottom surface of the housing160 to seal a first end of the housing 160.

The top cap 166 is fixedly coupled to a top surface of the housing 160to seal a second end of the housing 160. The fluid ports 170, 172 aredisposed on the top cap 166 over first and second apertures,respectively, extending through the top cap 166 such that the fluidports 170, 172 fluidly communicate with the first and second apertures,respectively. The top cap 166 further includes grooves 230, 231, 232,233, 234, 235, 236, 237 extending therethrough that communicate with thegrooves 209, 210, 212, 214, 216, 217, 218, 220, respectively in thehousing 160 for receiving corresponding graphite sheets therein.

During operation, refrigerant flows through the fluid port 170 and intothe interior region 162 of the housing 160 and then through theserpentine flow path defined therein and then out through the fluid port172. The refrigerant extracts heat energy from the housing 160 to coolthe housing 160 and the graphite sheets, that further cools the batterycells in the battery module 20.

Referring to FIGS. 2, 3 and 4, the cooling manifold 142 is provided toconduct heat energy from the graphite sheets into a refrigerant flowingthrough the cooling manifold 142. The cooling manifold 142 includes anextruded housing 240, a top cap 241, a bottom cap 242, and fluid ports243, 244. The housing 240, the top cap 241, the bottom cap 242, and thefluid ports 243, 244 can be constructed from at least one of aluminum,copper, silver, gold, and alloys thereof. It should be noted that thestructure of the cooling manifold 142 is identical to the coolingmanifold 140 discussed above. The housing 240 defines grooves 250, 251,252, 253, 254, 255, 256, 257 extending therein for receivingcorresponding extension portions of graphite sheets therein.

The bottom cap 242 is fixedly coupled to a bottom surface of theextruded housing 240 to seal a first end of the housing 240.

The top cap 241 is fixedly coupled to a top surface of the housing 240.The fluid ports 243, 244 are disposed on the top cap 241 over first andsecond apertures, respectively, extending through the top cap 241 suchthat the fluid ports 243, 240 fluidly communicate with the first andsecond apertures, respectively. The top cap 241 further includes grooves260, 261, 262, 263, 264, 265, 266, 267 extending therethrough thatcommunicate with the grooves 250, 251, 252, 253, 254, 255, 256, 257,respectively in the housing 240.

During operation, refrigerant flows through the fluid port 243 and intothe interior region of the housing 240 and then through the serpentineflow path defined therein and then through the fluid port 244. Therefrigerant extracts heat energy from the housing 240 to cool thehousing 240 and the graphite sheets coupled thereto, that further coolsthe battery cells.

Referring to FIGS. 9, 13 and 14, a flowchart of a method formanufacturing the cooling manifold 140 in accordance with anotherexemplary embodiment will now be explained.

At step 272, an extrusion device 268 extrudes a housing 160 having aninterior region 162. The extruded housing 160 has a first plurality ofgrooves 210, 212, 214, 216, 218, 220 extending from a first surface ofthe extruded housing 160 into the housing 160. The grooves do notfluidly communicate with the interior region 162. Further, the firstplurality of grooves are configured to receive a portion of a thermallyconductive member (e.g., the graphite sheet 80) therein to conduct heatenergy from the thermally conductive member to the extruded housing 160.

At step 273, a milling device 271 mills out end portions of the extrudedhousing 160 within the interior region 162 to form a serpentine flowpath within the housing 160. For example, the milling device 271 millsout portions of a first end of the extruded housing 160 to form openregions 400, 402, 404, 406 therein. Further, the milling device 271mills out portions of a second end of the extruded housing 160 to formopen regions 408, 410, 412, 414 therein. The serpentine flow path withinthe housing 160 is defined by the open regions 400, 402, 404, 406, 408,410, 412, 414 and the flow channels 180, 182, 184, 186, 188, 190, 192,194.

At step 274, an operator brazes the top cap 166 to a first end of theextruded housing 160 to seal the first end utilizing a brazing device269. The top cap 166 has first and second apertures extendingtherethrough.

At step 275, the operator brazes the bottom cap 168 to a second end ofthe extruded housing 160 to seal the second end utilizing the brazingdevice 269.

At step 276, the operator brazes a first fluid port 170 to the top cap166 such that the first fluid port fluidly communicates with the firstaperture in the top cap 166 utilizing the brazing device 269.

At step 277, the operator brazes a second fluid port 172 to the top cap166 such that the second fluid port 172 fluidly communicates with thesecond aperture in the top cap 166 utilizing the brazing device 269.

Referring again to FIG. 1, the compressor 22 is configured to pump arefrigerant through the conduit 28 into the battery module 20 inresponse to a control signal from the microprocessor 40. As shown, theconduit 28 is fluidly coupled to the compressor 22 and the ports 170,243 of the battery module 20. The conduit 30 is fluidly coupled to theports 172, 244 of the battery module 20 and the condenser 24. Afterexiting the battery module 20, the refrigerant is further pumped throughthe conduit 30 to the condenser 24.

The condenser 24 is provided to extract heat energy from the refrigerantflowing therethrough to cool the refrigerant. As shown, a conduit 32 isfluidly coupled between the condenser 24 and the compressor 22. Afterexiting the condenser 24, the refrigerant is further pumped through theconduit 32 to the compressor 22.

The temperature sensor 36 is provided to generate a signal indicative ofa temperature level of the battery module 20 that is received by themicroprocessor 40.

The fan 38 is provided to urge air past the condenser 24 to cool thecondenser 24 in response to a control signal from the microprocessor 40.As shown, the fan 38 is disposed proximate to the condenser 24. In analternative embodiment, the condenser 24 is a liquid to refrigerantcondenser.

The microprocessor 40 is provided to control operation of the batterysystem 10. In particular, the microprocessor 40 is configured togenerate control signals for controlling operation of the compressor 22and the fan 38, in response to a signal from the temperature sensor 36,as will be explained in greater detail below.

Referring to FIG. 15, a flowchart of a method for cooling a batterymodule in accordance with another exemplary embodiment will now beexplained. For purposes of simplicity, the method will be describedutilizing a single battery cell and a pair of graphite sheets in abattery module. Of course, additional battery cells and graphite sheetscould be utilized.

At step 280, the temperature sensor 36 generates a first signalindicative of a temperature of the battery module 20 that is received bythe microprocessor 40. The battery module 20 includes the battery cell80, graphite sheets 102, 104, and cooling manifolds 140, 142. Thegraphite sheets 102, 104 are disposed on first and second sides,respectively, of the battery cell 80. The cooling manifolds 140, 142 arecoupled to the graphite sheets 102, 104, respectively.

At step 282, the microprocessor 40 generates a second signal to inducethe compressor 22 to pump refrigerant into the cooling manifolds 140,142 of the battery module 20 when the first signal indicates thetemperature of the battery module 20 is greater than a thresholdtemperature level.

At step 284, the microprocessor 40 generates a third signal to inducethe fan 38 to blow air across the condenser 24 to cool the condenser 24when the first signal indicates the temperature of the battery module 20is greater than the threshold temperature level. The condenser 24 isfluidly coupled to the cooling manifolds 140, 142.

At step 286, the graphite sheets 102, 104 conduct heat energy from thebattery cell 80 into the graphite sheets 102, 104 to cool the batterycell 20.

At step 288, the cooling manifolds 140, 142 conduct heat energy from thegraphite sheets 102, 104 into the cooling manifolds 140, 142 and furtherconduct the heat energy into the refrigerant flowing through the coolingmanifolds 140, 142.

At step 290, the condenser 24 receives the refrigerant from the coolingmanifolds 140, 142 of the battery module 20 and extracts the heat energyfrom the refrigerant.

At step 292, the refrigerant is routed from the condenser 24 back to thecompressor 22.

Referring to FIG. 16, a battery system 310 for generating electricalpower in accordance with another exemplary embodiment is illustrated.The battery system 310 includes a battery module 320, a pump 322, a heatexchanger 324, a cold plate 325, a reservoir 326, a fan 337, conduits328, 330, 331, 332, 334, a temperature sensor 336, a refrigerant system338, and a microprocessor 340. The primary difference between thebattery system 310 and the battery system 10 is that the battery system310 utilizes a coolant instead of a refrigerant to cool the batterymodule 320.

The battery module 320 has an identical structure as the battery module20 discussed above.

The pump 322 is configured to pump a coolant through the conduit 328into the battery module 320 in response to a control signal from themicroprocessor 340. As shown, the conduit 328 is fluidly coupled betweenthe pump 322 and the battery module 320, and the conduit 330 is fluidlycoupled between the battery module 320 and the heat exchanger 324. Afterexiting the battery module 320, the coolant is further pumped throughthe conduit 330 to the heat exchanger 324.

The heat exchanger 324 is provided to extract heat energy from thecoolant flowing therethrough to cool the coolant. As shown, a conduit331 is fluidly coupled between the heat exchanger 324 and the cold plate325. After exiting the heat exchanger 324, the coolant is further pumpedthrough the conduit 331 to the cold plate 325.

The fan 337 is provided to urge air past the heat exchanger 324 to coolthe heat exchanger 324 in response to a control signal from themicroprocessor 340. As shown, the fan 337 is disposed proximate to theheat exchanger 324.

The cold plate 325 is provided to extract heat energy from the coolantflowing therethrough to further cool the coolant. As shown, a conduit322 is fluidly coupled between the cold plate 325 and the reservoir 326.After exiting the cold plate 325, the coolant is further pumped throughthe conduit 332 to the reservoir 326.

The reservoir 326 is provided to store at least a portion of the coolanttherein. As shown, a conduit 334 is fluidly coupled between thereservoir 326 and the pump 322. After exiting the reservoir 326, thecoolant is further pumped through the conduit 334 to the pump 322.

The temperature sensor 336 is provided to generate a signal indicativeof a temperature level of the battery module 320 that is received by themicroprocessor 340.

The refrigerant system 338 is provided to cool the heat exchanger 324 inresponse to a control signal from the microprocessor 340. As shown, therefrigerant system 338 is operably coupled to the cold plate 325.

The microprocessor 340 is provided to control operation of the batterysystem 310. In particular, the microprocessor 340 is configured togenerate control signals for controlling operation of the pump 322, thefan 337, and the refrigerant system 338 in response to a signal from thetemperature sensor 336, as will be explained in greater detail below.

Referring to FIGS. 17-18, a flowchart of a method for cooling thebattery module 320 in accordance with another exemplary embodiment isprovided. For purposes of simplicity, the method will be describedutilizing a single battery cell and a pair of graphite sheets in abattery module. Of course, additional battery cells and graphite sheetscould be utilized.

At step 360, the temperature sensor 336 generates a first signalindicative of a temperature of the battery module 320 that is receivedby the microprocessor 340. The battery module 320 includes a batterycell, first and second graphite sheets, and first and second coolingmanifolds. The first and second graphite sheets are disposed on firstand second sides, respectively, of the battery cell. The first andsecond cooling manifolds are coupled to the first and second graphitesheets, respectively.

At step 362, the microprocessor 340 generates a second signal to inducethe pump 322 to pump coolant from the reservoir 326 into the first andsecond cooling manifolds of the battery module 320 when the first signalindicates the temperature of the battery module 320 is greater than athreshold temperature level.

At step 363, the microprocessor 340 generates a third signal to inducethe fan 337 to blow air across the heat exchanger 324 to cool the heatexchanger 324 when the first signal indicates the temperature of thebattery module 320 is greater than the threshold temperature level. Theheat exchanger 324 is fluidly coupled to first and second coolingmanifolds of the battery module 320.

At step 364, the microprocessor 340 generates a fourth signal to inducethe refrigerant system 338 to pump a refrigerant through a portion ofthe cold plate 325 to cool the cold plate 325 when the first signalindicates the temperature of the battery module 320 is greater than thethreshold temperature level. The cold plate 325 is fluidly coupled tothe heat exchanger 324.

At step 366, the first and second graphite sheets conduct heat energyfrom the battery cell into the first and second graphite sheets,respectively, to cool the battery cell.

At step 368, the first and second cooling manifolds conduct heat energyfrom the first and second graphite sheets, respectively, into the firstand second cooling manifolds and further conduct the heat energy intothe coolant flowing through the first and second cooling manifolds,respectively.

At step 370, the heat exchanger 324 receives the coolant from the firstand second cooling manifolds of the battery module 320 therein andextracts the heat energy from the coolant flowing therethrough.

At step 371, the cold plate 325 receives the coolant from the heatexchanger 324 and extracts the heat energy from the coolant flowingtherethrough.

At step 372, the reservoir 326 receives the coolant from the cold plate325 and the coolant is routed from the reservoir 326 back to the pump.

The battery systems, battery modules, and the method for cooling thebattery module provide a substantial advantage over other systems,modules, and methods. In particular, the battery systems, batterymodules and method provide a technical effect of cooling a battery cellin the battery module utilizing a graphite sheet coupled to a coolingmanifold that effectively removes heat energy from the battery cell,while maintaining a relatively thin profile of the battery module.

While the invention has been described with reference to exemplaryembodiments, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiments disclosed for carrying thisinvention, but that the invention will include all embodiments fallingwithin the scope of the appended claims. Moreover, the use of the terms,first, second, etc. are used to distinguish one element from another.Further, the use of the terms a, an, etc. do not denote a limitation ofquantity, but rather denote the presence of at least one of thereferenced items.

What is claimed is:
 1. A battery module, comprising: a battery cellhaving a generally rectangular-shaped body portion, the generallyrectangular-shaped body portion having a first flat side and a secondflat side; a first graphite sheet having a first flat panel portion anda first extension portion, the first flat panel portion disposed on thefirst flat side of the battery cell that conducts heat energy from thebattery cell into the first graphite sheet to cool the battery cell, thefirst extension portion extending from a first end of the first flatpanel portion; a first cooling manifold thermally coupled to the firstgraphite sheet that conducts heat energy from the first graphite sheetinto the first cooling manifold, the first cooling manifold having agroove extending therein configured to receive the first extensionportion therein, the first flat panel portion of the first graphitesheet being disposed perpendicular to the first cooling manifold, thefirst flat side of the battery cell being disposed perpendicular to thefirst cooling manifold, the first cooling manifold further configured toreceive a fluid that flows therethrough to conduct heat energy from thefirst cooling manifold into the fluid; and a second graphite sheethaving a second flat panel portion and a second extension portion, thesecond flat panel portion disposed on the second flat side of thebattery cell that conducts heat energy from the battery cell into thesecond graphite sheet to cool the battery cell, the second extensionportion extending from a first end of the second flat panel portion; anda second cooling manifold thermally coupled to the second graphite sheetthat conducts heat energy from the second graphite sheet into the secondcooling manifold, the battery cell and the first and second graphitesheets being disposed between the first and second cooling manifolds,the second cooling manifold having a groove extending therein configuredto receive the second extension portion therein, the second flat panelportion being disposed perpendicular to the second cooling manifold, thefirst flat side of the battery cell being disposed perpendicular to thesecond cooling manifold, the second cooling manifold further configuredto receive the fluid that flows therethrough to conduct heat energy fromthe second cooling manifold into the fluid.
 2. The battery module ofclaim 1, wherein the first graphite sheet has a polyethylene coatingthereon.
 3. The battery module of claim 1, wherein the first graphitesheet has a thickness in range of 0.5 mm to 2.0 mm.
 4. The batterymodule of claim 1, wherein the first cooling manifold has a housing anda plurality of flow channels within the housing that define a serpentineflow path within the housing, the fluid flowing through the serpentineflow path.
 5. The battery module of claim 4, wherein the first coolingmanifold is constructed from at least one of aluminum, copper, silver,and gold.
 6. A battery system, comprising: a battery module having abattery cell, first and second graphite sheets, and first and secondcooling manifolds; the battery cell having a generallyrectangular-shaped body portion, the generally rectangular-shaped bodyportion having a first side and a second side; the first graphite sheethaving a first flat panel portion and a first extension portion, thefirst flat panel portion disposed on the first side of the battery celland conducts heat energy from the battery cell into the first graphitesheet to cool the battery cell, the first extension portion extendingfrom a first end of the first flat panel portion, the first extensionportion having a first portion, a second portion, and a third portion;the first portion extending from an end of the first flat panel portionin a first direction substantially perpendicular to the first flat panelportion, the second portion extending from an end of the first portionin a second direction substantially parallel to the first flat panelportion, the third portion extending from an end of the second portionin a third direction substantially parallel to the first portion, thefirst flat panel portion of the first graphite sheet being disposedperpendicular to the first cooling manifold; the first cooling manifoldis thermally coupled to the first graphite sheet and conducts heatenergy from the first graphite sheet into the first cooling manifold,the first cooling manifold having a groove extending therein configuredto receive the first extension portion therein, the first coolingmanifold further configured to receive a refrigerant that flowstherethrough to conduct heat energy from the first cooling manifold intothe refrigerant; the second graphite sheet having a second flat panelportion and a second extension portion, the second flat panel portiondisposed on the second side of the battery cell that conducts heatenergy from the battery cell into the second graphite sheet to cool thebattery cell, the second extension portion extending from a first end ofthe second flat panel portion, the second flat panel portion beingdisposed perpendicular to the second cooling manifold and parallel tothe first flat panel portion; the second cooling manifold thermallycoupled to the second graphite sheet that conducts heat energy from thesecond graphite sheet into the second cooling manifold, the secondcooling manifold having a groove extending therein configured to receivethe second extension portion therein, the second cooling manifoldfurther configured to receive the refrigerant that flows therethrough toconduct heat energy from the second cooling manifold into therefrigerant; a condenser fluidly coupled to the battery module, thecondenser configured to receive the refrigerant from the first andsecond cooling manifolds of the battery module and to extract heatenergy from the refrigerant, the condenser further fluidly coupled to acompressor and configured to route the refrigerant to the compressor;and the compressor further fluidly coupled to the first cooling manifoldof the battery module, the compressor configured to pump the refrigerantinto the first and second cooling manifolds.
 7. The battery system ofclaim 6, further comprising: a temperature sensor configured to generatea first signal indicative of a temperature of the battery module; and amicroprocessor operably coupled to the temperature sensor, themicroprocessor configured to generate a second signal to induce thecompressor to pump the refrigerant into the first and second coolingmanifolds when the first signal indicates the temperature of the batterymodule is greater than a threshold temperature level.
 8. A batterysystem, comprising: a battery module having a battery cell, first andsecond graphite sheets, and first and second cooling manifolds; thebattery cell having a generally rectangular-shaped body portion, thegenerally rectangular-shaped body portion having a first side and asecond side; the first graphite sheet having a first flat panel portionand a first extension portion, the first flat panel portion disposed onthe first side of the battery cell and conducts heat energy from thebattery cell into the first graphite sheet to cool the battery cell, thefirst extension portion extending from a first end of the first flatpanel portion, the first flat panel portion of the first graphite sheetbeing disposed perpendicular to the first cooling manifold; the firstcooling manifold is thermally coupled to the first graphite sheet andconducts heat energy from the first graphite sheet into the firstcooling manifold, the first cooling manifold having a groove extendingtherein configured to receive the first extension portion therein, thefirst extension portion having a first portion, a second portion, and athird portion; the first portion extending from an end of the first flatpanel portion in a first direction substantially perpendicular to thefirst flat panel portion, the second portion extending from an end ofthe first portion in a second direction substantially parallel to thefirst flat panel portion, the third portion extending from an end of thesecond portion in a third direction substantially parallel to the firstportion, the first cooling manifold further configured to receive acoolant therethrough to conduct heat energy from the first coolingmanifold into the coolant; the second graphite sheet having a secondflat panel portion and a second extension portion, the second flat panelportion disposed on the second of the battery cell that conducts heatenergy from the battery cell into the second graphite sheet to cool thebattery cell, the second extension portion extending from a first end ofthe second flat panel portion, the second flat panel portion beingdisposed perpendicular to the second cooling manifold and parallel tothe first flat panel portion; the second cooling manifold thermallycoupled to the second graphite sheet that conducts heat energy from thesecond graphite sheet into the second cooling manifold, the secondcooling manifold having a groove extending therein configured to receivethe second extension portion therein, the second cooling manifoldfurther configured to receive the coolant that flows therethrough toconduct heat energy from the second cooling manifold into the coolant; aheat exchanger fluidly coupled to the battery module, the heat exchangerconfigured to receive the coolant from the first and second coolingmanifolds of the battery module therein and to extract heat energy fromthe coolant flowing therethrough; a cold plate fluidly coupled to theheat exchanger, the cold plate configured to extract heat energy fromthe coolant flowing therethrough; a reservoir fluidly coupled betweenthe cold plate and a pump, the reservoir configured to receive thecoolant from the cold plate and to route the coolant to the pump; andthe pump further fluidly coupled to the first and second coolingmanifolds of the battery module, the pump configured to pump the coolantfrom the reservoir into the first and second cooling manifolds.
 9. Thebattery module of claim 1, wherein the first cooling manifold has ahousing with a plurality of flow channels therein, the plurality of flowchannels fluidly communicating with one another, the fluid flowingthrough the plurality of flow channels to conduct the heat energy fromthe first cooling manifold into the fluid.
 10. The battery system ofclaim 6, wherein the first cooling manifold has a housing with aplurality of flow channels therein, the plurality of flow channelsfluidly communicating with one another, the refrigerant flowing throughthe plurality of flow channels to conduct the heat energy from the firstcooling manifold into the refrigerant.
 11. The battery system of claim6, wherein the first cooling manifold has a housing with a serpentineflow path therein, the refrigerant flowing through the serpentine flowpath to conduct the heat energy from the first cooling manifold into therefrigerant.
 12. The battery system of claim 8, wherein the firstcooling manifold has a housing with a plurality of flow channelstherein, the plurality of flow channels fluidly communicating with oneanother, the coolant flowing through the plurality of flow channels toconduct the heat energy from the first cooling manifold into thecoolant.
 13. The battery system of claim 8, wherein the first coolingmanifold has a housing with a serpentine flow path therein, the coolantflowing through the serpentine flow path to conduct the heat energy fromthe first cooling manifold into the coolant.
 14. The battery system ofclaim 8, wherein the first and second sides of the generallyrectangular-shaped body portion comprise first and second flat sides,respectively.
 15. The battery module of claim 1, wherein the firstextension portion includes a first portion, a second portion, and athird portion; the first portion extending from an end of the first flatpanel portion in a first direction substantially perpendicular to thefirst flat panel portion, the second portion extending from an end ofthe first portion in a second direction substantially parallel to thefirst flat panel portion, the third portion extending from an end of thesecond portion in a third direction substantially parallel to the firstportion.
 16. The battery module of claim 1, wherein the first and secondcooling manifolds extend substantially parallel to one another, andextend perpendicular to the first flat side of the first graphite sheetand perpendicular to the first flat side of the second graphite sheet.17. The battery system of claim 6, wherein the first and second coolingmanifolds extend substantially parallel to one another, and extendperpendicular to the first side of the first graphite sheet andperpendicular to the first side of the second graphite sheet, thebattery cell being disposed between the first and second coolingmanifolds.
 18. The battery system of claim 8, wherein the first andsecond cooling manifolds extend substantially parallel to one another,and extend perpendicular to the first side of the first graphite sheetand perpendicular to the first side of the second graphite sheet, thebattery cell being disposed between the first and second coolingmanifolds.